future trends


efficient, cost savings could hopefully be passed on to travellers, while the overall transportation carbon footprint will be reduced.


TURNING UP THE HEAT Soft carbon felt has also long been the standard for use as thermal insulation in high temperature vacuum furnaces and inert gas electric furnaces. Once heated to a high temperature, carbon fibre becomes a pure carbon thermal insulator, wrapping the furnace interior like a blanket. During this collaboration, Kinloch and Morgan will be looking into how the carbon can be weaved to reflect the heat more efficiently. A crucial element of this research project is


looking at how to use carbon felt within the solar panel industry, testing graphene or nanotubes to enhance insulating properties. The solar cell market is expanding at a rapid rate; annual worldwide market growth rates are projected at 20 per cent for the foreseeable future. Solar cell production relies on the production of silicon ingots produced in a high- temperature furnace; expansion of ingot production requires larger furnaces, requiring more carbon insulation. Cost pressures on the steps of solar cell


production are intensifying as solar cells become commoditised. For carbon insulation producers like Morgan, that translates into a need to develop more thermally insulating material and at lower cost.


CARBON COMPOSITES UNDER PRESSURE Pumping water is a huge industry and quite simply cannot afford to fail without severe social consequences. One of the key areas in keeping the industry’s pumps going are the seals and bearings. These parts undergo huge amounts of pressure to


ensure no leaks occur, while pumping water in high volumes, and are used from large-scale industrial pumps all the way through to pumps in coffee machines.


However, water pumping takes its toll on


mechanical systems due to water’s lack of natural lubrication capabilities. This is where carbon materials really excel, as they are self- lubricating. The planar sheets of carbon in graphite structures can slide relative to each other, relieving stress at material interfaces like those at mechanical seal interfaces in pumps. This reduction in friction lowers the required energy to pump the water. Not only do carbon seals and bearings reduce


energy usage during the pumping process, but they are also safer and more hygienic. If carbon materials aren’t used, then invariably a secondary lubricant needs to be added into the pumping process. This brings the risk of mixing chemicals into the solution - for example lubricants mixing into coffee from the coffee machine pose a health risk to the user. Research shows that 20 per cent of the industrial


energy consumption is expended through pumping operations; thus, even incremental improvements in pumping efficiency would result in significant savings. Professor Kinloch’s work will focus on the fundamental mechanisms within carbon materials that dictate friction and wear at the interfaces; Morgan’s strategy is to use this added understanding to create longer lasting seals and bearings.


DIAMOND IN THE ROUGH During this research project, Professor Kinloch will collaborate with Morgan Advanced Materials through its new Carbon Science Centre of Excellence at Penn State University in the USA. Being awarded a research chair is an honour for Professor Kinloch and having the Royal Academy of Engineering offering its resources into this project is an incredible opportunity. As a strong supporter of manufacturing and


education in the UK, Professor Kinloch, together with Morgan, is eager to find carbon-carbon composite materials to help bring step changes across many industries. T&TH


February 2020 /// Testing & Test Houses /// 27


❱❱ Improved conductivity in railway power collection systems, far left, could be achieved with carbon- carbon composite strips; the use of composite materials in large industrial pumping systems, left, relieves stress at joints and interfaces


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